Experimental studies on dry machining behavior of Ti-6Al-4V using carbide, cermet, and SiAlON tools
SARTHAK PRASAD SAHOO SAURAV DATTA
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Traditional dry machining of ‘difficult-to-cut’ titanium alloy Ti-6Al-4V has always been a challenging task. This is due to its lower thermal conductivity, strong work-hardening tendency, and extreme chemical reactivity. These causes adverse machining effects including premature tool failure, evolution of hugecutting temperature, machine tool chatter, and disappointing surface integrity of the machined work part. Selection of compatible tool material, appropriate tool geometric parameters, and adequate control of cutting parameters are of vital importance towards achieving satisfactory machining yield. In this context, performances of MT-CVD TiCN/Al2O3 bi-layered coated carbide, PVD TiN/TiCN/TiN multi-layered coated cermet, and CVD TiCN/Al2O3 bi-layered coated SiAlON inserts are studied during dry machining of Ti-6Al-4V within cutting speed range 50-130 m/min; at constant feed ~ 0.1 mm/rev, and depth-of-cut ~ 0.35 mm. Approximate tool-tip temperature (maximum value) attained during operation, magnitude of tangential cutting force, and width offlank wear progression are measured. Detailed study on wear morphology of worn-out inserts, chip’s micro/ macro morphology, and surface integrity of the machined product are carried out. It is experienced that cermet tool performs better than remaining two counterparts in purview of lower tool-tip temperature, reduced flank wear, and better machined surface integrity.
SARTHAK PRASAD SAHOO1 SAURAV DATTA1
Volume 48, 2023
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